Material
Band saw boxes are made of any wood; from common white pine to exotic ebony, from whole logs to glued-together boards. Whichever wood you choose, these band saw boxes start as a thick, solid block. For my example, I started with a large spalted maple board. (Spalting is caused from fungi growing on trees or lumber before they dry out. When the wood dries completely, the fungus dies off, leaving behind a streaked multi colored-pattern. Spalting leaves a fantastic figure to the wood, but often softens and destroys parts of the wood. *warning* Because of fungus in the saw dust, Spalting can cause health risks. Take common sense measures to protect your lungs.)
Tools and equipment:
Band saw
3/4 resaw band saw blade
1/8 band saw blade for cutting curves
clamps
wood glue
miter saw or any saw to cut to across grain
belt sander
oscillating sander or drill press with sanding drum
sandpaper grits 60-220
finish of choice: I used Shellac
Step One:
Roughing Out the Project
Before we start cutting the wood, my safety warning. If your blades are dull, you will be forced to push harder and the harder you push the more likely you will cut yourself when you make a mistake. Not IF you make a mistake....when. Always use blades that are sharp, never dull. Not only is it dangerous, but a dull blade will twist sideways, easily messing up your cut. If you think you might be doing something dangerous, stop. Think how you might get hurt and how you might cut the wood safer. Don’t learn the hard way that time saved by skipping precautions can result in three months healing and a lost finger. Be smart. You can only make ten mistakes.